OEM 2004 Toyota RAV4 Clutch Master Cylinder

2004 Toyota RAV4 Parts Questions & Experts Answers

• Q: How to service and repair the Clutch Master Cylinder on 2004 Toyota RAV4?

  A: The wiper assembly must be removed before using pliers to detach the reservoir hose clip and unfastening the hose from the inlet union while catching fluid in a container. Special Service Tool: 09023-00100 enables the disconnection of the clutch line while catching fluid in a container. First remove the clip and pin with needle-nose pliers and afterward take out the master cylinder by unscrewing the 2 nuts then pull it out while also removing the gasket and pedal stay bracket and master cylinder bracket. To disassemble the inlet union begin by tapping its slotted spring pin using a pin punch combined with a hammer to remove it before taking off the grommet from the inlet union. After opening the lock nut you should take out both the clevis and lock nut before removing the boot and extracting the snap ring with snap ring pliers by pushing the push rod until you remove both the push rod and washer. Finish assembly by taking the cylinder piston along with its spring from the cylinder assembly. The piston assembly procedure begins with applying lithium soap base glycol grease to all parts followed by inserting the piston assembly with spring into the cylinder. Then install the push rod with the washer inside the piston where it needs to be secured by a snap ring. The first step includes installing the boot to the cylinder followed by setting the lock nut and clevis temporarily before installing a new grommet and inlet union to the cylinder body through a slotted spring pin installation process. The installation process starts with adding the gasket along with the pedal stay bracket and master cylinder bracket to the master cylinder followed by securing it with two nuts which need torquing to 12 Nm (120 kgf-cm, 9 ft. lbs.) then connecting the push rod to the clutch pedal with the pin and pin clip. The clutch line installation requires Special Service Tool: 09023-00100, which demands 15 Nm (155 kgf-cm, 11 ft. lbs.) torque when using this tool along with a 30 cm (11.81 inch) length torque wrench. Screw the inlet union reservoir hose while orienting the mark in an upward direction and fasten it using pliers and clip. The installation of wiper assembly should be followed by brake fluid addition to the reservoir before performing clutch system bleeding and adjusting clutch pedal position to check for fluid leaks.